Transport and alignment system for producing variable thickness collations

RELATED INVENTIONS

p-0002This patent application relates to commonly-owned, co-pending application Ser. No. 12/604,721 entitled “STITCHER/STAPLER FOR BINDING MULTI-SHEET COLLATIONS AND METHOD OF OPERATING THE SAME” and commonly-owned, co-pending application Ser. No. 12/604,797 entitled “RECONFIGURABLE STITCHER FOR BINDING CONSECUTIVE VARIABLE THICKNESS COLLATIONS”.

FIELD OF THE INVENTION

p-0003The present invention relates to apparatus for conveying stacked sheets of material, and more particularly, to a system for aligning the peripheral edges of a stacked collation while being conveyed by a transport mechanism such as those employed in high volume mail piece inserter systems.

BACKGROUND OF THE INVENTION

p-0004Various apparatus are employed for arranging sheet material in a package suitable for use or sale in commerce. One such apparatus, useful for describing the teachings of the present invention, is a mail piece inserter system employed in the fabrication of high volume mail communications, e.g., mass mailings. Such mailpiece inserter systems are typically used by organizations such as banks, insurance companies and utility companies for producing a large volume of specific mail communications where the contents of each mailpiece are directed to a particular addressee. Also, other organizations, such as direct mailers, use mailpiece inserters for producing mass mailings where the contents of each mail piece are substantially identical with respect to each addressee. Examples of inserter systems are the 8 series, 9 series, and APS™ inserter systems available from Pitney Bowes Inc. located in Stamford, Conn., USA.

p-0005In many respects, a typical inserter system resembles a manufacturing assembly line. Sheets and other raw materials (i.e., a web of paper stock, enclosures, and envelopes) enter the mailpiece inserter as inputs. Various modules or workstations in the mailpiece inserter work cooperatively to process the sheets until a finished mail piece is produced. The precise configuration of each inserter system depends upon the needs of each customer or installation.

p-0006Typically, mailpiece inserters prepare mail pieces by arranging preprinted sheets of material into a collation, i.e., the content material of the mail piece, on a transport deck. The collation of preprinted sheets may continue to a chassis module where additional sheets or inserts may be added to a targeted audience of mail piece recipients. From the chassis module the fully developed collation may continue to a stitcher module where the sheet material may be stitched, stapled or otherwise bound. Subsequently, the bound collation is placed into a mailpiece envelope and conveyed to yet other stations for further processing. That is, the envelopes may be closed, sealed, weighed, sorted and stacked. Additionally, the inserter may include a postage meter for applying postage indicia based upon the weight and/or size of the mail piece.

p-0007<figref idrefs="DRAWINGS">FIGS. 1</figref><i>a</i>-<b>1</b><i>c </i>show the relevant components of a prior art chassis module/station <b>200</b> of an inserter system. The figures show the chassis module <b>200</b> conveying a sheet material <b>212</b> along a transport deck <b>214</b> (omitted from <figref idrefs="DRAWINGS">FIG. 1</figref><i>a </i>to reveal underlying components). The transport deck <b>214</b> includes a drive mechanism <b>216</b> for displacing the sheet material <b>212</b> as it slides over the transport deck <b>214</b>. In <figref idrefs="DRAWINGS">FIG. 1</figref><i>c</i>, the transport deck <b>214</b> includes a low friction surface <b>214</b>S having a pair of parallel grooves or slots <b>214</b>G formed therein. Riding in the grooves or through the slots <b>214</b>G are fingers <b>216</b>F which extend orthogonally from the surface <b>214</b>S of the deck <b>214</b>.

p-0008Referring to <figref idrefs="DRAWINGS">FIGS. 1</figref><i>a</i>-<b>1</b><i>c</i>, the fingers <b>216</b>F are driven by a belt or chain <b>218</b>_C1which, in turn, wraps around a drive sprocket or gear <b>218</b>G. Furthermore, the fingers <b>216</b>F₁are spaced in equal length increments while the fingers <b>216</b>F₂, of adjacent chains <b>218</b>_C1, <b>218</b>_C2are substantially aligned, i.e., laterally across the transport deck <b>214</b>. As such, a substantially rectangular region or pocket is established between the fingers <b>216</b>F₁, <b>216</b>F₂.

p-0009Above the transport deck <b>214</b> are one or more feeder mechanisms <b>220</b>A, <b>220</b>B (two are shown for illustration purposes) which are capable of feeding inserts <b>222</b>, i.e., sheet material, to the transport deck <b>214</b>. The inserts <b>222</b> may be laid to build a collation <b>212</b> or may be added to the sheet material <b>212</b> (i.e., a partial collation) initiated upstream of the transport deck <b>214</b>. A controller (not shown) issues command signals to the feeder mechanisms <b>220</b>A. <b>220</b>B to appropriately time the feed sequence such that the inserts <b>222</b> are laid in the rectangular region <b>224</b> between the fingers <b>216</b>F₁, <b>216</b>F₂. More specifically, as each pair of lateral fingers <b>216</b>F₁, <b>216</b>F₂is driven within the grooves or slots <b>214</b>G, one edge of the sheet material <b>212</b> is engaged to slide the collation <b>212</b> along the transport deck <b>214</b>. As the sheet material <b>212</b> passes below the feeding mechanisms <b>220</b>A, <b>220</b>B, other sheets or inserts <b>222</b> are added. At the end of the transport deck <b>214</b>, the fingers <b>216</b>F₁, <b>216</b>F₂drop beneath the transport deck <b>214</b> such that the collation (i.e., the combination of the sheet material and inserts <b>222</b>) may proceed to subsequent processing stations.

p-0010While the drive mechanism <b>216</b> of the prior art provides rapid transport of collated sheet material <b>212</b>, <b>222</b>, the stacked sheets/inserts <b>222</b> fed by the feeding mechanisms <b>220</b>A, <b>220</b>B can become misaligned in the rectangular space or pocket <b>124</b> provided between the fingers <b>216</b>F₁, <b>216</b>F₂. That is, inasmuch as the pocket <b>224</b> is oversized to accept the sheets or inserts <b>222</b>, the inserts <b>222</b> can become misaligned due to a lack of positive registration surfaces on all sides of the collation <b>212</b>, <b>222</b>.

p-0011Various mechanisms are employed to vary the pocket size, i.e., sometimes referred to as the “pitch”, between the chassis fingers. The ability to change pitch not only enables greater efficiency, i.e., a greater number of pockets for inserts, but also minimizes the misalignment of inserts being laid on a collation. Notwithstanding the ability to minimize pocket size, it will be appreciated that without positive restraint on all free edges of the collation, individual sheets or inserts will be misaligned. Consequently, prior art inserters commonly employ complex registration mechanisms or jogging devices to align the free edges of a collation. For example, inserters may employ a series of swing arms which pivot onto the transport deck, i.e., into the conveyance path of the collation. The swing arms engage and align the leading edge of a collation, i.e., the edge opposite the fingers. While the swing arms effectively maintain alignment of the collation, the mechanical complexity associated with the pivoting mechanism is a regular source of maintenance, jamming and/or failure.

p-0012In the absence of such swing arms, an inserter may employ other jogging mechanisms to align the edges of the collation. Such jogging mechanisms often employ a complex arrangement of rotating cams/discs which tap or “jog” each edge by a predetermined displacement. While such rotating cam mechanisms are useful for aligning relatively thin collations, e.g., less than fifty (50) sheets of material, thick collations can be more difficult to align due to the weight of the stacked sheets. That is, inasmuch as the weight increases the frictional forces developed between individual sheets of material, i.e., especially the lowermost sheets of the collation, it is more difficult to effect the requisite movement between sheets to align the edges of the collation. As a consequence, the edges of misaligned sheets can be damaged or torn by the motion/action of such prior art jogging mechanisms.

p-0013Additionally, many mailpiece inserters employ mechanisms, e.g., a stitcher or a stapler, to bind the collations as they travel along the transport and alignment system. These binding mechanisms must be manually adjusted depending upon the anticipated thickness of a collation within a particular mail run. That is, the size of the stitch or staple must be anticipated to penetrate and bind the collation. This operation requires significant operator intervention and does not accommodate consecutive collations which vary in thickness. With respect to the latter, stitchers/staplers of the prior art cannot bind collations which vary in thickness from one collation having a thickness of, for example, one-half inch (½″), to a subsequent or consecutive collation having a thickness of, for example, three-quarter inches within the same mail run. This is due to the fixed or constant thickness staples used in, or stitches produced by, the stitcher/stapler. While some small variation may be accommodated by the same size stitch or staple, stitcher/staplers of the prior art are generally limited to binding constant thickness collations.

p-0014In view of the foregoing it will be appreciated that transport and alignment systems, especially those which employ binding mechanisms along the feed path, are limited in terms of their throughput or processing speed. That is, in view of the time required to jog, align, bind and transport collations along the feed path, these systems can only process a fixed number of collations per unit time.

p-0015A need, therefore, exists for a system for transporting, aligning and binding consecutive variable thickness collations which improves reliability, increases throughput, and minimizes mechanical complexity.

SUMMARY OF THE INVENTION

p-0016A system is provided for aligning multi-sheet collations including a conveyance system having a transport deck for supporting and conveying the multi-sheet collation along a feed path. The system includes a first pair of registration members disposed orthogonal to the feed path and defining a processing station along the feed path. The registration members further define registration surfaces which are repositionable from an active position above the transport deck to an idle position below the transport deck. A first displacement mechanism raises and lowers the registration members into and out of the active and idle positions, and oscillates at least one of the registration surfaces forward and aft in a direction parallel to the feed path when the registration member is in its active position. A processor controls the motion of the conveyance system relative to the registration members of the alignment station, and controls the first displacement mechanism to: (i) raise the registration surfaces into the active position, (ii) oscillate the registration surfaces to align the opposing edges of the multi-sheet collation, and (iii) lower the registration surfaces into the idle position to facilitate conveyance of the aligned multi-sheet collation along the feed path.

BRIEF DESCRIPTION OF THE DRAWINGS

p-0017Further details of the present invention are provided in the accompanying drawings, detailed description, and claims.

p-0018<figref idrefs="DRAWINGS">FIG. 1</figref><i>a </i>is a perspective view of a prior art chassis drive mechanism employed in a mail piece inserter system.

p-0019<figref idrefs="DRAWINGS">FIG. 1</figref><i>b </i>is a profile view of the prior art chassis drive mechanism shown in <figref idrefs="DRAWINGS">FIG. 1</figref><i>a </i>including feed mechanisms for building a sheet material collation.

p-0020<figref idrefs="DRAWINGS">FIG. 1</figref><i>c </i>is a broken-away isometric view of the prior art chassis drive mechanism of <figref idrefs="DRAWINGS">FIG. 1</figref><i>a </i>to more clearly show chain driven fingers for conveying the sheet material collation along a transport deck.

p-0021<figref idrefs="DRAWINGS">FIG. 2</figref> is an isometric view of a stitcher/stapler module having a transport and alignment system including a pair of belts having pusher fingers to convey a multi-sheet collation along a feed path, and a system of alignment mechanisms disposed alongside and between the fingers to jog and align the edges of the collation.

p-0022<figref idrefs="DRAWINGS">FIG. 3</figref> is a block diagram of various components of a mailpiece inserter system including a processor for controlling the operation of a stitcher/stapler module and processing thickness data/sheet count information derived from one of a variety of sources.

p-0023<figref idrefs="DRAWINGS">FIG. 4</figref> is a broken away isometric view of the stitcher/stapler module of <figref idrefs="DRAWINGS">FIG. 2</figref> to reveal the relevant details of the transport and alignment system including an feed input station for stacking a multi-sheet collation, and first and second processing stations disposed downstream of the feed input station for aligning the leading, trailing and lateral side edges of the multi-sheet collation.

p-0024<figref idrefs="DRAWINGS">FIG. 5</figref> is a schematic side view of the first and second processing stations each including pairs of repositionable alignment mechanisms which may be: (i) extended upward between the first and second conveyor belts to jog/align the leading and trailing edges of the multi-sheet collation, and (ii) retracted below the support surfaces of the conveyor belts to facilitate to transport along the feed path immediately prior to, and following alignment of, the multi-sheet collation.

p-0025<figref idrefs="DRAWINGS">FIGS. 6</figref><i>a </i>and <b>6</b><i>b </i>depict exploded and assembled views, respectively, of a typical trailing edge alignment mechanism including a four-bar linkage arrangement for displacing a registration member of the alignment mechanism from an idle position below the conveyor belts to an active position above the conveyor belts.

p-0026<figref idrefs="DRAWINGS">FIGS. 7</figref><i>a </i>and <b>7</b><i>b </i>depict exploded and assembled views, respectively, of a typical leading edge alignment mechanism including a four-bar linkage arrangement for displacing the registration member from the idle to active positions, and a linear guide/actuator assembly for imparting pure linear motion to the registration member when jogging the multi-sheet collation during alignment operations.

p-0027<figref idrefs="DRAWINGS">FIGS. 8</figref><i>a </i>through <b>8</b><i>d </i>depict schematic views of a reconfigurable stitch head adapted to vary the length of each binding stitch based upon thickness data/sheet count information of the multi-sheet collation.

DETAILED DESCRIPTION

p-0028The following detailed description discusses three related, yet patentably distinct inventions related to processing sheet material collations. A first relates to a stitcher/stapler for binding multi-sheet collations and method for controlling the same. A second relates to a transport and alignment system for producing variable thickness collations and a third relates to an adjustable stitcher for binding consecutive variable thickness collations. While each will be discussed under a separate heading, the description relates and defines elements common to all of the inventions.

p-0029Further, the inventions will be described in the context of a stitcher/stapler for use in a mailpiece inserter. In the broadest sense, however, the stitcher/stapler, transport/alignment system, and adjustable stitcher of the present invention may be integrated with, and/or receive input from, any sheet handling apparatus adapted to produce/process multi-sheet collations. While the inventions may be particularly useful for processing/producing mail communications, it should be appreciated that the inventions are broadly applicable to any apparatus/system which requires binding, transport and alignment of stacked sheets of material, i.e., a multi-sheet collation. As used herein, the term “collation” is any multi-sheet stack of material, i.e., having at least two (2) sheets, such as that required for fabricating, books, pamphlets, mailpiece content material etc.

h-0007Stitcher/Stapler for Binding Multi-Sheet Collation and Method of Operation

p-0030In <figref idrefs="DRAWINGS">FIGS. 2 and 3</figref>, a stitcher/stapler <b>10</b> is adapted to stack, transport, align and bind consecutive multi-sheet collations <b>12</b> which vary in thickness. That is, the stitcher/stapler <b>10</b> is adapted to process consecutive collations which comprise as few as two (2) sheets to as many as one-hundred and fifty (150) sheets. It should be appreciated, however, that total number of sheets in a particular collation will generally be governed by the ability of a processing station to bind sheet material.

p-0031In the described embodiment, the stitcher/stapler <b>10</b> includes three serially-arranged processing stations including an feed input station <b>14</b>, a first processing station <b>16</b>, and a second processing station <b>18</b> The stitcher/stapler <b>10</b> receives sheet material <b>12</b>S from an upstream module (not shown) of a sheet handling apparatus, e.g., a mailpiece inserter <b>24</b> (see <figref idrefs="DRAWINGS">FIG. 3</figref>), and accumulates/stacks of sheet material at the feed input station <b>14</b>. The thickness of the multi-sheet collation <b>12</b> is determined to ascertain which of the subsequent processing stations <b>16</b>, <b>18</b> will be most effective to bind the multi-sheet collation <b>12</b>. The first processing station <b>16</b>, immediately downstream of the feed input station <b>14</b>, includes a stitcher <b>20</b> (described and illustrated in greater detail below) to bind the collation by a variable length “stitch”, i.e., a length of wire which is cut/formed to produce a pair of prongs connected by a central web (similar to a staple, however, the ends of each prong are not sheared so as to form a penetrating point). The second processing station <b>18</b> includes a stapler <b>22</b> which binds the collation by a fixed length “staple”, i.e., a conventional U-shaped fastener having a pair of penetrating legs connected by a central crown.

p-0032The principle difference between the two, i.e., the stitcher <b>20</b> of the first processing station <b>16</b> and the stapler <b>22</b> of the second processing station <b>18</b>, relates to the capacity and/or ability of each to bind a collation. The stitcher <b>20</b> provides the capability to bind many collations before a requirement to reload a supply of stitching wire. That is, the stitcher <b>20</b> employs a relatively large spool of wire to provide a large supply of stitching material to bind multiple collations/documents. However, due to the requirement to shape each stitch from a supply of wire spool, the gauge of the wire and/or its yield strength properties, must be relatively low to facilitate the formation of the stitch, i.e., bending the wire to shape. A stapler <b>22</b>, on the other hand, provides the ability to bind thick collations, e.g., a thickness greater than about forty-five thousands of an inch (0.45″) or greater than about ninety (90) sheets of bond grade paper, but is limited in terms of the number of collations/documents that can be bound. With respect to the latter, the staples, which are “preformed”, are fabricated from high yield strength, high stiffness materials. As a result, the legs of each staple can be fabricated to a length sufficient to penetrate thick collations without buckling. However, since the staples are preformed and packaged in strips having a finite number, only a small number of collations may be bound before the stapler <b>22</b> must be reloaded. In view of these differences, the stitcher/stapler module <b>10</b> of the present invention obtains information concerning the thickness of the multi-sheet collation such that each may be directed to the most appropriate downstream station for subsequent processing. This feature is discussed in greater detail in the subsequent paragraphs.

p-0033In <figref idrefs="DRAWINGS">FIG. 3</figref>, thickness/sheet count information <b>30</b> is used for several operations of the stitcher/stapler <b>10</b> including operations which: (i) select the processing station <b>16</b>, <b>18</b> best suited to bind the collation <b>12</b>, (ii) control the transport and alignment of the multi-sheet collations <b>12</b> at each of the processing stations <b>16</b>, <b>18</b>, and (iii) control the stitching operation at the first processing station <b>16</b> (i.e., the length of stitch, spacing between the anvil/clincher and the striker/ram, etc.) Specifically, the thickness information <b>30</b> may be obtained by (i) reading a scan code data <b>32</b> printed on the first sheet of the multi-sheet collation <b>12</b>, (ii) employing a sheet counter <b>34</b> in combination with sheet thickness data input by an operator, (iii) obtaining the number of sheets directly from the job data <b>36</b> of the mail run (i.e., from the application program code which generates each sheet printed in the mail run), (iv) directly measuring the thickness via a thickness measurement probe <b>38</b>, once the collation <b>12</b> has been stacked. In the described embodiment, a scanner (not shown), upstream of the stitcher/stapler module <b>10</b>, reads the scan code data <b>32</b> to obtain the number of sheets contained in the collation <b>12</b>. A processor <b>40</b>, controlling the operation of the mail piece inserter <b>24</b> (including the stitcher/stapler module <b>10</b>), determines the thickness of the collation <b>12</b> as the product of the number of individual sheets <b>12</b>S multiplied by the thickness of each sheet. An operator may be prompted i.e., via a keyboard or other input device <b>42</b> to enter the type or characteristics (i.e., weight, bond, copy, etc.), of the sheet material such that the processor <b>40</b> may calculate the thickness of the collation <b>12</b> to be bound.

p-0034The processor <b>40</b> uses the thickness data/sheet count information to convey the multi-sheet collation <b>12</b> from the input feed station <b>14</b> to the stitcher <b>20</b> at the first processing station <b>16</b>, or to the stapler <b>22</b> at the second processing station <b>18</b>. That is, the processor <b>40</b> is responsive to a thickness value signal TS and, if the thickness of the collation is greater than (or less than) a threshold value (X), the collation <b>12</b> is transported to one of the processing stations <b>16</b>, <b>18</b>. In the described embodiment, if it is determined that the collation <b>12</b> is less than or equal to about forty-five thousands inches (0.45″) in thickness, the collation <b>12</b> is transported to the first station <b>16</b> for processing. Therein, the collation <b>12</b> is bound by the stitcher <b>20</b> which is capable of varying the length of the stitch such that the stitch optimally extends through the collation. That is, the wire of the stitcher <b>20</b> is cut to a length such that the prongs thereof extends through the collation and the anvil of the stitcher <b>20</b> clinches the ends to an optimal length, i.e., sufficiently long to capture all of the sheets without overlapping the ends of each prong. In the described embodiment, the stitcher <b>20</b> is capable of varying the length of each stitch, i.e., from one collation to a subsequent collation. While this aspect of the invention will be discussed in greater detail below i.e., when describing the reconfigurable stitcher illustrated in <figref idrefs="DRAWINGS">FIGS. 8</figref><i>a </i>though <b>8</b><i>d</i>, suffice it to say at this juncture, that the stitcher <b>20</b> is adapted to: (i) vary the length of the wire which forms each stitch, (ii) center the web relative to the striker/ram which drives the stitch through the collation, and (iii) vary the strike distance i.e., the distance between the striker/ram and the anvil.

p-0035If it is determined that the thickness of the collation <b>12</b> is greater than about forty-five thousands inches (0.45″), the collation <b>12</b> is transported to the second station <b>18</b> for processing. Therein, the collation <b>12</b> is bound by the stapler <b>22</b> which is capable of penetrating the thick collation without bending/buckling. That is, since each staple is fabricated from a high yield strength material, the legs of each staple are highly stabile in buckling and penetrate the collation without bending.

h-0008Transport and Alignment System for Producing Variable Thickness Collations

p-0036As discussed above, the multi-sheet collation <b>12</b> is conveyed along a feed path FP of the stitcher/stapler <b>10</b> to one of the processing stations <b>16</b>, <b>18</b> depending upon the collation thickness/sheet count information <b>30</b>. In <figref idrefs="DRAWINGS">FIGS. 4 and 5</figref>, the transport and alignment system comprises first and second belts <b>54</b><i>a</i>, <b>54</b><i>b </i>(best seen in <figref idrefs="DRAWINGS">FIG. 4</figref>) which wrap around, and are driven by, a plurality of rolling elements <b>56</b>. That is, one or more rotary drive motors M is coupled to, and drives, at least one of the rolling elements <b>56</b> associated with each of the belts <b>54</b><i>a</i>, <b>54</b><i>b</i>. In the described embodiment, the belts <b>54</b><i>a</i>, <b>54</b><i>b </i>are cogged to engage teeth disposed about the periphery of the rolling elements <b>56</b>. The first and second belts <b>54</b><i>a</i>, <b>54</b><i>b </i>slideably engage, and are each supported by, a rigid support structure disposed beneath the respective belts <b>54</b><i>a</i>, <b>54</b><i>b </i>to mitigate catenation thereof between the rolling elements <b>56</b>. In the described embodiment, the rigid support structures are elongate bars <b>58</b> (see <figref idrefs="DRAWINGS">FIG. 2</figref>) having a width dimension (transverse to the feed path FP of the collation <b>12</b>) approximately equal to the width of each belt. As a consequence, the belts <b>54</b><i>a</i>, <b>54</b><i>b </i>and bars <b>58</b> define a space or gap therebetween to allow for binding apparatus, i.e., the stitcher <b>20</b> and stapler <b>22</b>, to access the underside of the multi-sheet collation <b>12</b>. Furthermore, the spacing between the first and second belts <b>54</b><i>a</i>, <b>54</b><i>b </i>mitigates skewing of the multi-sheet collation <b>12</b>.

p-0037Each of the belts <b>54</b><i>a</i>, <b>54</b><i>b </i>includes a plurality of spaced-apart fingers <b>60</b> which are aligned along the conveyance/feed path FP to convey the multi-sheet collation <b>12</b> from the feed input station <b>14</b> to one of the downstream processing stations <b>16</b>, <b>18</b>. The fingers <b>60</b> project upwardly, i.e., orthogonally, from each of the belts <b>54</b><i>a</i>, <b>54</b><i>b </i>and engage the trailing edge <b>12</b>T of the multi-sheet collation <b>20</b> at two points. Furthermore, the belts <b>54</b><i>a</i>, <b>54</b><i>b </i>are aligned across the feed path FP and driven in unison to “push” the collation <b>12</b> along the feed path FP to one of the two processing stations <b>16</b>, <b>18</b>.

p-0038In <figref idrefs="DRAWINGS">FIGS. 4 and 5</figref>, perspective and side views, respectively, of the belts <b>54</b><i>a</i>, <b>54</b><i>b </i>are shown to reveal opposing alignment mechanisms <b>62</b><i>a</i>, <b>62</b><i>b </i>comprising pairs of registration members <b>64</b><i>a</i>, <b>64</b><i>b </i>disposed along the feed path FP and between the first and second conveyor belts <b>54</b><i>a</i>, <b>54</b><i>b</i>. Functionally, the alignment mechanisms <b>62</b><i>a</i>, <b>62</b><i>b </i>are operative to align the opposed edges, e.g., leading and trailing edges, of the multi-sheet collation <b>12</b> as each collation comes to rest at one of the processing stations <b>16</b>, <b>18</b>. Once aligned, the collation <b>12</b> is bound by either the stitcher <b>20</b> or stapler <b>22</b>, depending upon which processing station <b>16</b>, <b>18</b> has been selected to bind the collation <b>12</b>, i.e., as determined by the processor <b>40</b>.

p-0039More specifically, and referring <figref idrefs="DRAWINGS">FIGS. 4</figref>, <b>5</b>, and <b>6</b><i>a </i>through <b>7</b><i>b</i>, each of the registration members <b>64</b><i>a</i>, <b>64</b><i>b </i>extends transversely across the feed path FP and has a generally L-shaped cross section defined by a base <b>66</b> and a registration wall <b>68</b> disposed orthogonally from the base <b>66</b>. Each registration wall <b>68</b> defines a registration surface <b>68</b>R which is repositionable from an idle position (shown in dashed lines in <figref idrefs="DRAWINGS">FIG. 6</figref><i>b</i>), below the support surface <b>54</b>S (also referred to as the “transport deck”) of each of the belts <b>54</b><i>a</i>, <b>54</b><i>b</i>, to an active position (shown in solid lines in <figref idrefs="DRAWINGS">FIG. 6</figref><i>b</i>) above the support surface <b>54</b>S of the belts <b>54</b><i>a</i>, <b>54</b><i>b</i>. In the idle position, the collation <b>12</b> moves over one or both of the registration members <b>64</b><i>a</i>, <b>64</b><i>b </i>and may be conveyed from the feed input station <b>14</b> to either of first or second processing stations <b>16</b>, <b>18</b>. Alternatively, with all of the registration members <b>64</b><i>a</i>, <b>64</b><i>b </i>in the idle position, the collation <b>12</b> may be conveyed across the entire stitcher/stapler <b>10</b> to another downstream processing station, i.e., without being bound at either the first or second processing stations <b>16</b>, <b>18</b>.

p-0040In the active position, at least one of the registration members <b>64</b><i>a</i>, <b>64</b><i>b </i>is adapted to oscillate forward and aft, i.e., along the feed path FP, to align the edges of the collation <b>12</b>. In the described embodiment, the downstream registration member <b>64</b><i>b </i>(see <figref idrefs="DRAWINGS">FIGS. 4 and 7</figref><i>b</i>) of each pair, i.e., the registration member <b>64</b><i>b </i>in contact with the leading edge <b>12</b>L of the collation <b>12</b>, oscillates forward and aft to align the sheets of the collation <b>12</b>. Although, it should be appreciated that either or both of the registration members <b>64</b><i>a</i>, <b>64</b><i>b </i>may be displaced to align the collation <b>12</b>.

p-0041To ensure complete and accurate registration of large collations, e.g., those having more than ninety (90) sheets or having a thickness greater than about 0.3 inches, the downstream registration member <b>64</b><i>b </i>of each pair oscillates for eight (8) cycles and is displaced a distance of about 0.25 inches with each cycle. However, to increase throughput, i.e., the number of collations processed (i.e., bound via the stitcher <b>20</b> or stapler <b>22</b>), the number of cycles may be varied depending upon the thickness of the collation <b>12</b>. For example, a collation <b>12</b> having as few as ten (10) sheets, or a thickness less than about 0.1 inches, the registration member <b>64</b><i>b </i>may be cycled three (3) times. Similar to the selection of the appropriate processing station <b>16</b>, <b>18</b>, thickness data <b>30</b>, or the number of sheets in each collation <b>12</b>, is used by the stitcher/stapler module <b>10</b> to determine the optimum number of cycles for aligning the sheets of each collation <b>12</b>. That is, the processor <b>40</b> acquires the thickness information <b>30</b> and varies the number of cycles depending upon the collation thickness or sheet count.

p-0042To further improve throughput, the processor <b>40</b> may control the conveyance system, (i.e., the belts <b>54</b><i>a</i>, <b>54</b><i>b</i>, rolling elements <b>56</b> and drive motor M), to use the first and second processing stations <b>16</b>, <b>18</b> as buffer stations. That is, when the stitcher/stapler <b>10</b> is not active, i.e., functioning only as a transport system, the processing stations <b>16</b>, <b>18</b> may serve to hold/retain collations <b>12</b> (unbound collations) so that other mailpiece inserter stations e.g., folding, insertion and/or print stations (not shown) downstream of the first and second processing stations <b>16</b>, <b>18</b> may process the mailpiece content material.

p-0043In <figref idrefs="DRAWINGS">FIGS. 5 through 7</figref><i>b</i>, each of the registration members <b>64</b><i>a</i>, <b>64</b><i>b </i>pivotally mounts to a first displacement mechanism <b>70</b> operative to: (i) raise and lower the registration members <b>64</b><i>a</i>, <b>64</b><i>b </i>into and out of the idle and active positions, and (ii) oscillate at least one of the registration members <b>64</b><i>a</i>, <b>64</b><i>b </i>to align the sheets of the collation <b>12</b>. In the described embodiment, the displacement mechanism <b>70</b> comprises a plurality of links <b>72</b>, <b>74</b> pivotally mounting at one end to an intermediate fitting <b>76</b>, and pivotally mounting at the other end to the base <b>66</b> of a respective one of the registration members <b>64</b><i>a</i>, <b>64</b><i>b</i>. The intermediate fitting <b>76</b> includes a mounting plate <b>78</b> and at least one arm <b>80</b><i>a </i>projecting upwardly therefrom. In the described embodiment, the intermediated fitting <b>76</b> includes a pair of clevis arms <b>80</b><i>a</i>, <b>80</b><i>b </i>projecting from each side of the mounting plate <b>78</b> for additional stability.

p-0044The mounting plate <b>78</b> of each intermediate fitting <b>76</b> is mounted to a center rail <b>10</b>R (see <figref idrefs="DRAWINGS">FIG. 4</figref>) of the stitcher/stapler <b>10</b> by a clamp attachment <b>82</b>. As such, the entire displacement mechanism <b>70</b> and respective one of the registration members <b>64</b><i>a</i>, <b>64</b><i>b </i>may be released, repositioned, and reaffixed to the rail <b>10</b>R via locking cams <b>84</b>. That is, to facilitate adjustment of the registration members <b>64</b><i>a</i>, <b>64</b><i>b</i>, i.e., the spacing therebetween to accommodate dimensional changes in the size of collations <b>12</b>, the locking cams <b>84</b> provide an ability to quickly disconnect/reconnect the displacement mechanism <b>70</b> along the center rail <b>10</b>R.

p-0045Each displacement mechanism <b>70</b> includes a first pneumatic actuator <b>86</b> which is disposed between the base <b>66</b> of the respective registration member <b>64</b><i>a </i>or <b>64</b><i>b</i>, and the mounting plate <b>78</b>. In the described embodiment, the first pneumatic actuator <b>86</b> includes a linear piston/cylinder disposed between the clevis arms <b>80</b><i>a</i>, <b>80</b><i>b </i>of the intermediate fitting <b>76</b>. A pneumatic valve <b>88</b> provides pressurized air PA₁(see <figref idrefs="DRAWINGS">FIG. 6</figref><i>b</i>) to the actuator <b>86</b> of respective displacement mechanism <b>70</b> to displace the registration wall <b>68</b> into and out of the idle and active positions.

p-0046In <figref idrefs="DRAWINGS">FIG. 6</figref><i>b</i>, an examination of the displacement mechanism <b>70</b> reveals that the links <b>72</b>, <b>74</b>, intermediate fitting <b>76</b>, and base <b>66</b>, produce a four-bar linkage defined by line segments AB, BC, CD and DA. The four-bar linkage arrangement can be configured, i.e., depending upon the length of the links <b>72</b>, <b>74</b> and the location of the respective pivot points A, B, C, D, to perform the dual functions of rotation and translation of the respective one of the registration members <b>64</b><i>a</i>, <b>64</b><i>b</i>. That is, the four-bar linkage arrangement can displace the respective one of the registration members <b>64</b><i>a</i>, <b>64</b><i>b </i>to rotate above and below the surface <b>54</b>S of the belts <b>54</b><i>a</i>, <b>54</b><i>b </i>while also producing a substantially linear displacement i.e., forward and aft along the feed path FP, to jog and align the edges <b>12</b>L, <b>12</b>E of the collation <b>12</b>. With respect to the latter, such linear displacement will be accompanied by a small angular displacement, which, depending upon the geometry of the stitcher/stapler <b>10</b>, may or may not be tolerated.

p-0047In <figref idrefs="DRAWINGS">FIGS. 7</figref><i>a </i>and <b>7</b><i>b</i>, pure linear translation of the displacement mechanism <b>70</b> may be effected by a linear guide <b>90</b> disposed in combination with a second pneumatic actuator <b>92</b>. More specifically, the linear guide <b>90</b> is disposed between the intermediate fitting <b>76</b> and the clamp attachment <b>82</b> and includes at least one sled fitting <b>94</b> affixed to the underside of the intermediate fitting <b>76</b>, i.e., to the underside of the mounting plate <b>78</b>, for slideably engaging a linear guide rail <b>95</b> affixed to an upper surface of the clamp attachment <b>82</b>. The second pneumatic actuator <b>92</b> is attached at one end, via a flange fitting <b>96</b>, to the clamp attachment <b>82</b>, and at the other end, via a bracket <b>97</b>, to the underside of the mounting plate <b>78</b>. A pneumatic valve <b>98</b> provides pressurized air PA₂(see <figref idrefs="DRAWINGS">FIG. 7</figref><i>b</i>)<i>to </i>the second pneumatic actuator <b>92</b> to effect linear translation of the displacement mechanism within the linear guide <b>90</b>. Recalling that only the registration members <b>64</b><i>b </i>associated with the leading edge of the collation <b>12</b> may be used to jog the collation <b>12</b>, only the displacement mechanism <b>70</b> associated with downstream registration member <b>64</b><i>b</i>, associate with each processing station <b>16</b>, <b>18</b> may be adapted to include the linear guide <b>90</b> and pneumatic actuator <b>92</b>.

p-0048Thus far, the transport and alignment system has been described in the context of a stitcher/stapler <b>10</b> having a requirement to jog and align the leading and trailing edges of the multi-sheet collation <b>12</b>. While the transport and alignment system may employ conventional alignment devices/apparatus for guiding/aligning the lateral side edges of the collation <b>12</b>, e.g., rotating cams or converging side rails (not shown), the present invention employs a novel side registration system <b>100</b>, seen in <figref idrefs="DRAWINGS">FIGS. 2 and 4</figref>, which spans all of the processing stations, i.e., the feed input station <b>14</b>, and the first and second processing stations <b>16</b>, <b>18</b>. More specifically, the side registration system <b>100</b> comprises a second pair of registration members <b>104</b><i>a</i>, <b>104</b><i>b </i>each having registration surfaces <b>104</b>R (only one of the registration members <b>104</b><i>b </i>is shown in <figref idrefs="DRAWINGS">FIG. 4</figref>) disposed adjacent each of the first and second conveyor belts <b>54</b><i>a</i>, <b>54</b><i>b</i>. The registration members <b>104</b><i>a</i>, <b>104</b><i>b </i>extend the length of the processing stations <b>14</b>, <b>16</b>, <b>18</b> and, similar to the first pair of registration members <b>64</b><i>a</i>, <b>64</b><i>b</i>, have a generally L-shaped cross sectional configuration. The spacing between the registration members <b>104</b><i>a</i>, <b>104</b><i>b</i>, i.e., the spacing across the feed path FP, may be adjusted to accommodate collations <b>12</b> which may vary in width dimension. Inasmuch as these registration members <b>104</b><i>a</i>, <b>104</b><i>b </i>do not cross the feed path, there is no requirement to raise or lower each relative to the surface <b>54</b>S of the conveyor belts <b>54</b><i>a</i>, <b>54</b><i>b</i>. On the other hand, similar to the first pair of registration members <b>64</b><i>a</i>, <b>64</b><i>b</i>, at least one of the second pair of registration members <b>104</b><i>a</i>, <b>104</b><i>b </i>is adapted to oscillate in a transverse direction, i.e., toward and away from the conveyor belts <b>54</b><i>a</i>, <b>54</b><i>b </i>to align the side edges <b>12</b>SE of the multi-sheet collation <b>12</b>. Although, it should be appreciated that either or both of the registration members <b>104</b><i>a</i>, <b>104</b><i>b </i>may be displaced to align the side edges <b>12</b>SE of the collation <b>12</b>.

p-0049In the described embodiment, a second displacement mechanism <b>106</b> is attached to each of the registration members <b>104</b><i>a</i>, <b>104</b><i>b </i>and at least one of the second displacement mechanisms <b>106</b> is operative to oscillate and jog the side edges of the multi-sheet collation <b>12</b>. While the second displacement mechanism <b>106</b> and registration members <b>104</b><i>a</i>, <b>104</b><i>b </i>may function to align the side edges <b>12</b>SE at any or all of the processing stations <b>14</b>, <b>16</b>, <b>18</b>, side registration of a collation <b>12</b> will generally commence at either the first or second processing stations <b>16</b>, <b>18</b> where the collation <b>12</b> will be bound, i.e., by the stitcher <b>20</b>, or stapler <b>22</b>. Similar to the first pair of registration members <b>64</b><i>a</i>, <b>64</b><i>b</i>, at least one of the second pair of registration members <b>104</b><i>a </i>or <b>104</b><i>b </i>is operative to cyclically or repetitively engage a lateral side edge <b>12</b>SE of the collation <b>12</b>. In the described embodiment, the displacement of each oscillation for aligning the side edges <b>12</b>SE will be about 0.25 inches, i.e., the same as the displacement required for aligning the leading and trailing edges <b>12</b>L, <b>12</b>T. The other of the registration members <b>104</b><i>a</i>, or <b>104</b><i>b </i>remains essentially stationary to react the impact forces generated by the opposing one of the registration members <b>104</b><i>a</i>, <b>104</b><i>b</i>. With respect to the latter, the second displacement mechanism <b>106</b> associated therewith is principally operational to adjust the location of the respective one of the displacement mechanisms <b>106</b>.

p-0050The processor <b>40</b> controls the second displacement mechanisms <b>106</b> associated with the side registration system <b>100</b>, i.e., to oscillate at least one of second pair of registration members <b>104</b><i>a</i>, <b>104</b><i>b</i>, using the same thickness data <b>30</b> or sheet count information obtained for cycling the first displacement mechanism <b>70</b>. That is, should the thickness data <b>30</b> or sheet count require eight (8) cycles by one or both of the first displacement mechanism <b>70</b>, e.g., collations <b>12</b> having more than ninety (90) sheets, then the processor <b>40</b> will command one or both of the second displacement mechanisms <b>106</b> to cycle by an equivalent number. Similarly, should the thickness data <b>30</b> or sheet count require three (3) cycles, the processor <b>40</b> will control the second displacement mechanism <b>106</b> accordingly. The number of cycles will generally decrease from a maximum of about eight (8) cycles to a minimum of about three (3) cycles as the thickness/sheet count, of the collation <b>12</b> decreases from greater than about ninety (90) sheets to a minimum of two (2) sheets. It will be recalled that such variation in the number of cycles, i.e., as a function of the collation thickness/sheet count, serves to optimize throughput.

p-0051The second displacement mechanism <b>106</b> may use any of a variety of actuators to displace and cycle the registration members <b>104</b><i>a</i>, <b>104</b><i>b</i>. In the described embodiment, the second displacement mechanism <b>106</b> employs a pair of linear actuators <b>108</b> (see <figref idrefs="DRAWINGS">FIG. 4</figref>) disposed at each end of the respective one of the registration members <b>104</b><i>a</i>, <b>104</b><i>b </i>to ensure proper alignment of the collation <b>12</b>, whether the collation <b>12</b> is processed at the first or second processing stations <b>16</b>, <b>18</b>.

h-0009Reconfigurable Stitcher for Binding Consecutive Variable Thickness Collations

p-0052As previously discussed, the thickness data/sheet count information <b>30</b> is used to control the stitching operation at the first processing station <b>16</b>. The thickness data/sheet count <b>30</b> may be generated by any of a variety of modules/sensor of the mailpiece inserter <b>24</b> or stitcher/stapler <b>10</b> including: (1) scan code data <b>32</b> (see <figref idrefs="DRAWINGS">FIG. 3</figref>) printed on a sheet of the mailpiece content material, e.g., the first sheet of each collation <b>12</b>, (ii) a sheet counter <b>34</b> in combination with sheet thickness data input by an operator, (iii) mail run data <b>36</b>, i.e., obtained directly from the application software (mail run data file) used to produce the content material, or (iv) a thickness measurement device, e.g., a thickness probe <b>38</b>.

p-0053In <figref idrefs="DRAWINGS">FIGS. 8</figref><i>a </i>through <b>8</b><i>d</i>, the stitcher <b>20</b> may be reconfigurable to vary the length of each binding stitch <b>120</b> based upon the thickness T of the multi-sheet collation <b>12</b>. More specifically, the stitcher <b>20</b> comprises a stitch head <b>122</b> disposed beneath the collation <b>12</b> and a clinch head or anvil <b>124</b> disposed above the collation <b>12</b>. Consequently, the stitcher <b>20</b> drives the prongs P (see <figref idrefs="DRAWINGS">FIG. 8</figref><i>d</i>) of each binding stitch <b>120</b> upwardly through the lowermost or bottom sheet <b>12</b>B while the clinch head <b>124</b> crimps the ends PE of each prong P against the top or uppermost sheet <b>12</b>U of the collation <b>12</b>. In the described embodiment, the stitch head <b>122</b> is disposed between the first and second conveyor belts <b>54</b><i>a</i>, <b>54</b><i>b</i>, though it will be appreciated that the stitch head may be disposed to either side of the belts <b>54</b><i>a</i>, <b>54</b><i>b</i>. Furthermore, while a single stitcher <b>20</b> is depicted, it will be appreciated that several stitchers <b>20</b> may be juxtaposed across the width, or disposed in tandem along the length, of the multi-sheet collation <b>12</b>, to bind the collation <b>12</b> at several locations.

p-0054In <figref idrefs="DRAWINGS">FIG. 8</figref><i>a</i>, the processor <b>40</b> receives thickness data <b>30</b> in connection with each collation <b>12</b> conveyed to the first processing station. The processor <b>40</b> uses this data/information <b>30</b> to determine the length of wire <b>120</b>W used to generate the respective binding stitch <b>120</b>, i.e., a stitch specifically tailored in length to bind a collation <b>12</b> of a particular thickness dimension T. The processor <b>40</b> issues a first signal to a first input actuator <b>134</b>, i.e., a rotary actuator, which advances wire <b>120</b>W, through the nip of a pair of rollers <b>128</b>, and across a pair of spaced-apart bending beams <b>130</b><i>a</i>, <b>130</b><i>b </i>of the stitch head <b>122</b>. Furthermore, the wire <b>120</b> is disposed beneath a forming block <b>132</b> which cooperates with the bending beams <b>130</b><i>a</i>, <b>130</b><i>b </i>to form the prongs P about the squared edges of the forming block <b>132</b>. Wire to form the stitch <b>120</b> may be drawn from a conventional spool <b>138</b> mounted to the housing of the stitcher/stapler <b>10</b>. In addition to the thickness T of the collation <b>12</b>, which determines the minimum length of the prongs P required to penetrate the collation <b>12</b>, other dimensions needed to perform this operation include: (i) the width of the web W, i.e., the length of wire between the prongs, and (ii) the end length LE (see <figref idrefs="DRAWINGS">FIG. 8</figref><i>d</i>) of the prong end PE i.e., the portion protruding through, and securing the collation.

p-0055The processor <b>40</b> issues a second signal S<b>2</b> to a second input actuator <b>140</b> to center the wire <b>120</b>W across the bending beams <b>130</b><i>a</i>, <b>130</b><i>b</i>. Additionally, the processor <b>40</b> issues a third signal S<b>3</b> to a third input actuator <b>142</b> to displace several components of the stitch head <b>122</b>, i.e., internal structure of the stitch head <b>122</b> which forms the stitch <b>120</b>, upwardly toward the underside of the collation <b>12</b>. That is, as third input actuator <b>142</b> strokes upwardly, portions of the upward displacement, denoted by lines D<b>1</b>, D<b>2</b> and D<b>3</b> actuate one or more connected elements.

p-0056A first portion of the stroke D<b>1</b> causes a shearing device <b>142</b> to cut the stitch wire <b>120</b>W. This motion can be conveyed directly to the shearing device <b>142</b> or via cams connected to one of the bending beams <b>130</b><i>a</i>, <b>130</b><i>b</i>. In <figref idrefs="DRAWINGS">FIG. 8</figref><i>b</i>, a second portion of the stroke D<b>2</b> displaces the bending beams <b>130</b><i>a</i>, <b>130</b><i>b </i>upwardly. In this portion of the displacement, the stitch wire <b>120</b>W falls, and is guided, within a pair of grooves <b>146</b><i>a</i>, <b>146</b><i>b </i>formed along the internal walls of the bending beams <b>130</b><i>a</i>, <b>103</b><i>b </i>to bend the stitch wire <b>120</b> about the squared ends of the forming block <b>132</b>. In addition to guiding the prongs P, the internal grooves <b>146</b><i>a</i>, <b>146</b><i>a </i>provide buckling stability as the prongs P penetrate the collation <b>12</b>.

p-0057In <figref idrefs="DRAWINGS">FIGS. 8</figref><i>b </i>and <b>8</b><i>c</i>, the displacement D<b>2</b> also causes the forming block <b>132</b> (shown in <figref idrefs="DRAWINGS">FIG. 8</figref><i>b</i>) to move away, (into or out of the plane of <figref idrefs="DRAWINGS">FIG. 8</figref><i>c</i>) such that the web W is free to move upwardly in the subsequent portion of the stroke D<b>3</b>. The second portion of the stroke D<b>2</b> terminates when the bending beams <b>130</b><i>a</i>, <b>130</b><i>b </i>abut the lowermost sheet of the collation <b>12</b>. That is, the ends of each of the bending beams <b>130</b><i>a</i>, <b>130</b><i>b </i>define a reference surface which will be used by the processor <b>40</b> to position the anvil <b>124</b> relative to the stitch head <b>122</b>. In the final or third portion of the stroke D<b>3</b>, a striker or ram <b>148</b> (see <figref idrefs="DRAWINGS">FIG. 8</figref><i>c</i>) engages the web W of the stitch <b>120</b> to drive the prongs P though the collation <b>12</b>. At the same time, i.e., while the lower portion of the stitcher <b>122</b> moves into position below the collation <b>12</b>, the processor <b>40</b> issues a fourth signal S<b>4</b> to a fourth input actuator <b>150</b> to lower the anvil or clincher <b>124</b>, (a displacement denoted by line D<b>4</b> in <figref idrefs="DRAWINGS">FIGS. 8</figref><i>c </i>and <b>8</b><i>d</i>) against the uppermost sheet of the collation <b>12</b>.

p-0058In <figref idrefs="DRAWINGS">FIG. 8</figref><i>d</i>, the motion of the striker <b>148</b> causes the prongs P to penetrate the collation <b>12</b> and crimp/clinch the ends PE of each prong P. In the described embodiment, the clincher <b>150</b> includes arcuate surfaces for securing the ends PE of the prongs, however, other clinching devices, including those which actively recurve the ends PE of the prong P, are contemplated.

p-0059In summary, the various embodiments described herein feature a stitcher/stapler <b>10</b> and/or a mailpiece inserter <b>24</b> capable of binding multi-sheet collations which vary in thickness. The thickness data/sheet count information <b>30</b> may be derived from various sources including a scan code <b>32</b>, sheet counter <b>34</b>, mail run data file <b>36</b> or thickness input device <b>38</b>. Throughput is enhanced by arranging the stations <b>14</b>, <b>16</b>, <b>18</b> in series and conveying a multi-sheet collation <b>12</b> to the apparatus, i.e., the stitcher <b>20</b> or stapler <b>22</b>, best suited to bind the collation based upon the thickness of the collation <b>12</b>. The serial arrangement of the processing stations <b>16</b>, <b>18</b> is made possible by a transport and alignment system having alignment mechanisms which may be raised and lowered into and out of idle and active positions, i.e., such that the collation may pass across each of the serial arranged stations <b>16</b>, <b>18</b>. Throughput is further enhanced by varying the number of cycles, i.e., oscillations associated with each registration of the registration members <b>64</b><i>a</i>, <b>64</b><i>b</i>, <b>104</b><i>a</i>, <b>104</b><i>b</i>, to align the leading, trailing and side edges <b>12</b>L, <b>12</b>T, <b>12</b>SE of the collation <b>12</b>. Finally, the stitcher <b>20</b> may also be reconfigured/adapted to vary the size of a binding stitch <b>120</b> to bind consecutive variable thickness collations. While prior art stitching apparatus must be adjusted manually to bind collations from one mail run to the next, e.g., stitching collations of a constant thickness for a multi-collation mail run, the stitcher <b>20</b> of the present invention is reconfigurable from one collation to the next in the same mail run. As a consequence, the stitcher/stapler <b>10</b>, when used in the context of, or in combination with, a mailpiece inserter <b>24</b>, is highly robust, adaptable and flexible i.e., in terms of the type and thickness of collations which can be produced.

p-0060It is to be understood that the present invention is not to be considered as limited to the specific embodiments described above and shown in the accompanying drawings. The illustrations merely show the best mode presently contemplated for carrying out the invention, and which is susceptible to such changes as may be obvious to one skilled in the art. The invention is intended to cover all such variations, modifications and equivalents thereof as may be deemed to be within the scope of the claims appended hereto.